T3 T4 Hybrid Turbo OHV

[Dono]

It takes time to gather the bits when your on a budget. I think your moving along really fast.
I think I was collecting parts for 6 months. Lots of little fittings and odds and ends to think about.

 

[Caejxr]

One thing I really want to do is a lot of insulating for heat on everything around the passenger side of the engine bay since the down pipe will run right through the gap by the floor and header. 3x the exhaust will be getting piped through that space than stock so I'm sure temperatures will get quite a bit higher.

 

[Dono]

Maybe header wrap the down pipe in the engine bay area. Also, once you get the turbo dialed in, a turbo blanket will help under hood temps.

 

[Caejxr]

Some of what I've been doing.

Intercooler is mounted with a sheet metal scoop. Feed pipe and inlet flange are welded and you see the mock up of the y where it meets the stock y which I'll be cutting. Oil drain I'll keep unobstructed to keep things easy for routine maintenance.

 

[Dono]

Looks awesome! It will be a nice short run to the intercooler from the outlet.
That turbo is a tight fit there.
Are you going to tap the oil pan for the oil return?

Im trying to picture in my head how the turbo and air filter will fit, and failing miserably.
Im sure you have a plan, and its going to be great use of space.

 

[Caejxr]

It's a pretty tight fit for sure. The adapter and braided flex pipe just squeeze past the shock mount for the outlet with not much to spare. I have a 3" to 4" 90 deg silicon reducer that lets me attach the filter/snorkel no problems. I'll get some pictures next time it's together again.

 

[Caejxr]

 

[Dono]

I get it. I'm really liking the location of that turbo. Do you see a spot you can get at your oil pan to punch a hole ant tap? The front dif creates challenges.

 

[Caejxr]

Ah, sorry I forgot to reply. Yes. I'll be tapping the pan on one of the raised parts between the bolts. Just to the passanger side of the crank pulley. I've got a weld on -10an bung that I'll be looking to get on there.

 

[Dono]

Make sure you detail how this goes please. I struggled with where, and how to do this.

 

[Caejxr]

Will do, I'm either going to try and weld it or if the pan doesn't cooperate, tap the hole and get a threaded fitting to put in. My biggest concern is shavings going in the pan but I'm going to follow the instructions for the vortec kit on the 1st gen explorer and also use heavy grease before threading then change the oil when it's all done to try and "wash" any out.

 

[Caejxr]

Alright, it's a rainy evening so I'm just hangin out on the couch. I decided to go the drill and tap route.

There in the picture is the 10an drain line, the 10an to 1/2" threaded bit came with some seals and a nut to go inside the pan but, since I'm tapping the aluminum I won't need it. Also shown there is my new tap wrench and 1/2" tap I also picked up a little tap and die set while I was at the store earlier. I'll be tapping the hole and threading it as one of the last bits of "fabricating" I'll be doing after I've got the exhaust pipe all in place and turbo bolted in.

Next week I'll cut the pipes and try to get the exhaust all in place I haven't put much time in to the down pipe yet as it's simpler than the inlet. We shall see if that pays off or costs more time...

 

[Caejxr]

Well, project funding today effectively got put on hold due to an unexpected trip to the men's warehouse with the wife. It's not all bad though. This will give me time to focus on getting the fuel pump in and exhaust lines finished. For now, injectors, maf, bov, and intercooler lines will have to wait.

 

[Caejxr]

Got some welding in today and the y pipe cut. V6 sounds beastly without the rest of the exhaust on. Sure will get old fast.

The inlet pipe with wastegate adapter is complete a little ugly but i welded it with some optimas... Wastegate will be just in front of the axle a little higher than the lower cross beam of the lift. Should get good airflow to keep it decently cool.

I have some minor welding left on the y to inlet collector where the pipe goes from 2" to 2.5. Should finish that tomorrow.. Then I'll put those together and the rest of this week will be for the down pipes completion. I'm going to try and use that adapter from the y that goes to an oval for the cat. I've pounded it into a 3" Dia circle and used a reducer to adapt it together.

So the inlet and down pipe are done. I have two more minor welds to do on the collector and ill be ready to mount the turbo and wastegate up. From there ill be tapping the threads and hole into the pan for the drain and post all that up. To follow that I'll be doing the fuel pump.

I'm kicking around the idea of dumping it after the cats or immediatly after the muffler but I don't want it to be annoying on the highway or too loud offroad as it goes hunting with me.

 

[Caejxr]

I'm starting to think I may need some sort of bracket to fix either the inlet pipe or turbo housing in place. I can create something from scratch but, I'm wondering if there are any ideas floating out there in the ones and zeros anyone may have off-hand?

 

[Dono]

If your going to mount the support bracket to the frame, you will need some kind of flex pipe in-between the manifold and turbo.

You should be supporting that turbo with something other than the exhaust manifold. It looks pretty tight around there, and its going to be a challenge. Other than that, I have nothing for you.

 

[Caejxr]

The flex pipe of the down pipe with the exit flange welded on. Currently it's hung up on that bolt im going to cut tomorrow after I pick up a few more cutting wheels.

That is the rest of the down pipe and the inlet collector. A few small tweaks tomorrow after the bolt is cut and the turbo and waste gate will be going in place.

Eventually I'll probably have some pipe bent for me and replace that cheap flex pipe. But for now it's exactly that, cheap.

 

[Dono]

Looks awesome!
That flex pipe is a beautiful thing for fabricating also. Once its all in place you can just run with it till there is an issue, and then replace it all with solid pipes, and there won't be any guess work in the bends.

It's coming along quickly.

 

[jd4242]

Can i ask what gears you have in that truck??

 

[Caejxr]

4.56